Process and Technology

AGI Denim employs state-of-the-art technology in vertically integrated processes, including garment manufacturing, fabric production, and spinning.

Garment

AGI Denim has 14 garment factories with 3 LEED-certified units, focusing on quality and speed.

Cutting

The denim fabric is cut into individual pieces based on the patterns. Precision is crucial during this stage to ensure that the pieces fit together accurately during the sewing process.

Sewing

This stage involves various processes that bring together the different components of a garment. AGI Denim has invested in numerous automation to increase efficiencies and reduce the inaccuracies involved in sewing.

Washing

Is at the heart of the garmenting process. AGI Denim has built up an arsenal of the latest wet and dry machines to bring the latest washing innovations to market.

Finishing

Our finishing is integral to our quality and inspection process as it is out final step to complete the garment before shipping to the customer.

Garment Capacity

LEED platinum and gold certified units

Production processes compliant with international standards of quality

44 robotic arms used for spray process

50 state-of-the-art high-speed laser machines

42 low liquor- ratio washing machines

In-house printing and embroidery facilities

130 sewing lines

111 washers

Fabric

AGI Denim develops and produces some of the most innovative denim for leading global brands. It has the capacity to make 55 million yards of denim fabric per year. It all starts with our fabric R&D Studio, where new fabrics are developed, sustainable practices are researched, and efficient production methods are sought out.

Ball Warping

Multiple yarn packages are combined into a large ball or warp sheet. This helps ensure an even distribution of yarn during the subsequent weaving process.

Rope Dyeing

Rope dyeing is a specific method of dyeing denim yarn that imparts unique characteristics to the final denim fabric. This technique is widely used in the denim industry, especially for creating the classic deep blue color associated with denim jeans.

Sizing

Sizing is an intermediate protective process which is done to prepare the yarn for the weaving process.

Weaving

The woven process involves interlacing the warp and weft yarns on a loom to create the denim fabric. Different weaving patterns, with the twill weave being the most common for denim, can be used to achieve specific textures and patterns.

Finishing

The unfinished denim fabric undergoes various finishing processes to achieve the desired characteristics. Finishing processes may include washing, softening, or treatments to create distressed or vintage looks.

Fabric Capacity

Capacity to make 60 million yards of denim fabric per year through our state-of-the-art denim mill

Environmentally sustainable practices and innovation

Spinning

AGI Denim is proud to add the first LEED-certified spinning unit in the country, designed according to Industry 4.0 principles. Our state-of- the-art new LEED-certified spinning has the capacity to produce 48 million pounds of yarn annually. In addition, keeping with our zero- waste focus, we also have the technology to recycle spinning waste into making yarn.

Blending

Fibers from different sources or with different properties may be blended together before the carding process. This ensures a more homogeneous mix of fibers in the subsequent spinning stages.

Carding

The selected cotton fibers are initially carded to remove impurities, align the fibers, and create a continuous web. Carding ensures a more consistent and clean starting material.

Combing

In some cases, the drawn fibers may undergo a combing process to remove shorter fibers and create a smoother, higher-quality yarn.

Roving

The drawn and, if applicable, combed fibers are then twisted and elongated to form a roving. The roving is a slightly twisted strand of fibers that serves as the precursor to the denim yarn.

Ring Spinning

The roving is further twisted and drafted using a ring spinning frame. Ring spinning is a common methoin denim production, as it allows for the production of high-quality, strong yarn.

Winding

The spun denim yarn is wound onto bobbins or cones for storage and transportation. Winding ensures that the yarn is well-organized and ready for the subsequent weaving process.